nice job. lots of work, but i understand your desire to keep your wheelset. I'm in the same boat, but i contacted Reynolds for my DV3K's, and they confirmed that they do make an 11-speed freehub for 2011 and later DV3k's, Assaults, Attacks and Strikes. Best of all, no redish is required for the wheel to work.

How would you machine the freehub to increase the depth? You have to machine the inner part of the splines so the cassette will seat all the way.I can't think of way to machine down in there without cutting farther into the flange than the amount required for the 11sp cassette.

Great work. If people think you're "ruining" parts then pffffft. Better to machine a freewheel body than ditch a whole wheel set you like. I like it.

_________________You can't be a real country unless you have a beer and an airline. It helps if you have some kind of a football team, or some nuclear weapons, but at the very least you need a beer.
-- Frank Zappa

Haha, what? So you machined BOTH parts, effectively knackering both, when you could have just machined the freebody.

I could not machine the grooves any deeper in the cassette body. The 1st picture of the hub shows the actual cassette body. The 2nd pic was taken off the web to emphasize the step in the splines on another type cassette body.

While I wanted to upgrade to 11 speed, I was not to happy with the fact all my wheels were now obsolete I could purchase (& did) a 11 speed Dura Ace C 24 Tubeless wheelset, no one made a 11 speed all carbon 50mm Tubeless wheelset.

_________________We're flying down mountains with just a bit of carbon and two skinny tires between ass and asphalt

I'm interested in this solution, but a little confused. When you say you machined 1mm of material off the inside of the last sprocket on the rear cassette, are you talking about Dura Ace and Ultegra that have composite carriers? Would it be possible to machine the same amount of material off a Sram 11 speed cassette to get the same result? I have two sets of Lightweight Gen 1 Shimano spec wheel sets that I'd love to use 11 speed with and this option sounds promising as long as once machined the cassette does not foul the spokes?

I think it'd be a bad idea to take 1mm off the back of a Red cassete. That aluminium sheet pressed in to the back of the cassette is not very thick.Their lower range cassettes have carriers like Shimano which would have more room for material removal.

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